UWO Mechanical Components Design For Mechatronic Systems (MSE 3380) Sample Problems - Solutions v3

MSE 3380
UWO
Sample Problems (v3)
1. [Stress analysis] A sign of dimensions 2.0 m 1.2 m is supported by a hollow circular

pole having outer diameter 220 mm and inner diameter 180 mm as shown in the left and
centre figures. The sign is offset 0.5 m from the centerline of the pole and its lower edge
is 6.0 m above the ground.
(a)
(b)
(c)
A wind pressure against the sign produces a resultant force, , that acts at the midpoint of
the sign (right figure) and is equal to the pressure, , times the area, sign , over which it
acts:
= sign = (2.0 kPa)(2.0 m 1.2 m) = 4.8 kN .
The line of action of is at height = 6.6 m above the ground and at distance = 1.5 m
from the centerline of the pole. Neglecting stress concentrations and the weight of all
components, determine:
(a) the moment of inertia, , polar moment of inertia, , cross-sectional of the pole, pole ,
and the relevant first moment of area for a hollow-semicircle given by,
2
= (23 13 ).
3
(b) the equivalent force-couple system (, , , , , ) at the centroid of the section

of interest.
(c) the normal and shear stress components acting on the element at .
(d) the normal and shear stress components acting on the element at .
(e) the principal stresses, maximum shear stress and corresponding normal stress at
(max , min , max ) geometrically using Mohrs circle.
(f) the principal stresses, maximum shear stress and corresponding normal stress at
(max , min , max ) using any method. Sketch two stress elements (at ) that illustrate
the principal and maximum shear stress states (explicitly identify their orientations).
Bonus: (+1 point) Determine if the pole will yield at using the maximum-distortionenergy (von Mises) criterion given = 60 MPa for the steel used.
Fernando Freitas Alves
ffreitas@uwo.ca
Jan 21, 2015 1/25
MSE 3380
UWO
SOLUTION
(a) Let the pole symbol be and the sign symbol be . Thus, we have the second moment
of area (or moment of inertia) with respect to the -axis to their centroids
= 2 d
2 dd
2 2
2
2
2 d

,
12
where = 2.0 m and = 1.2 m
= 0.288 m4
=
ext
2 dext
int
ext
2 dint
2
int
( sin )2 (dd)
0
0
2
( sin )2 (dd)
ext
= sin2 d 3 d
0
int
4
4 )
= (ext
int
,
4
220
180
mm = 0.110 m and ext =
mm = 0.090 m
2
2
63.5 106 m4 = 0.635 dm4
where ext =
and with respect to the -axis to their centroids

= 2 d
2 dd
2 2
2
2
2
=
=
3
,
12
where = 2.0 m and = 1.2 m
= 0.8 m4
ffreitas@uwo.ca
Jan 21, 2015 2/25
MSE 3380
UWO
ext
2 dext
int
ext
2 dint
2
2 (dd)
( cos )
0
0
2
int
( cos )2 (dd)
ext
= cos2 d 3 d
0
int
4
4 )
= (ext
int
,
4
220
180
mm = 0.090 m
2
2
63.5 106 m4 = 0.635 dm4 =
where ext =
Their polar second moment of area (or polar moment of inertia) are
= 2 d
= ( 2 + 2 )d
= 2 d + 2 d
= +
= (0.8 + 0.288) m4
= 1.088 m4
=
ext
2
2 dext
int
ext
0
0
2
2 (dd)
ext
= d
0
2 dint
int
2 (dd)
3 d
int
4
4 )
= (ext
int
2
= 2 = 2
2 (63.5 106 m4 )
= 127 106 m4 = 1.27 dm4
ffreitas@uwo.ca
Jan 21, 2015 3/25
MSE 3380
UWO
The cross-sectional area of the pole is

pole = = ext int
2 )
2
= (ext
int
,
220
180
mm = 0.090 m
2
2
12.6 103 m2 = 1.26 dm2
where ext =
The relevant first moment of area for a hollow-semicircle is given by

ext
int ()d ,
int
ext ()d
where () is the thickness in the -axis
ext int ,
ext
int
where is the top (or bottom) portion of the members

cross-sectional area, defined from the section where ()
is measured, and is the distance to the centroid of ,
measured from the neutral axis
Centroid of ext
Centroid of int
ext
int
ext
int
Neutral axis
int ()
ext ()
=[
ext
0 0
( sin )(dd)
0 0 int( sin )(dd)
] ext [
] int
ext
int
ext
= sin d
0
2 d
int
2 3
3
),
= (ext
int
3
220
180
mm = 0.090 m
2
2
401 106 m3 = 401 cm3
where ext =
ffreitas@uwo.ca
Jan 21, 2015 4/25
MSE 3380
UWO
(b) According to the illustrations and knowing that = 1.5 m and = 6.6 m, the
equivalent force-couple system (, , , , , ) at the point of the section is
(0, , 0, , 0, ) = (0 N, 4.8 kN, 0 N, 7.2 kNm, 0 Nm, 31.68 kNm)
= (0, 4.8, 0, 7.2, 0, 31.68) 103 [S. I. ]
=0
= 0
ffreitas@uwo.ca
= 0
Jan 21, 2015 5/25
MSE 3380
UWO
(c) The state of stress at the point is
where
ext
,
given the flexure (bending) due to
ext
=
(4.8 kN) (6.6 m) (0.110 m)
(63.5 106 m4 )
55 MPa
= 0 ,
since no force stress this direction
ext
,
given the torsion due to
ext
=
(4.8 kN) (1.5 m) (0.110 m)
(127 106 m4 )
6.2 MPa
ffreitas@uwo.ca
Jan 21, 2015 6/25
MSE 3380
UWO
(d) The state of stress at the point is
where
= = 0 ,
since no force stress these directions
ext
+
,

given the torsion and the transverse force due to
where = and = 2 (ext int )
ext
+
],
2 (ext int )
220
180
where ext =
mm = 0.090 m
2
2
=[
(4.8 kN)
(1.5 m) (0.110 m)
(401 106 m3 )
[
+
]
(127 106 m4 )
2 (63.5 106 m4 ) (0.110 m 0.090 m)
7.0 MPa
ffreitas@uwo.ca
Jan 21, 2015 7/25
MSE 3380
UWO
(e) Constructing the Mohrs circle, we got that
max
min
max
55.7 MPa
0.7 MPa
28.2 MPa
27.5 MPa (when = )
(f) Once there is no normal stress in the direction studied in the exercise (d), the maximum
shear stress is the same that is already calculated with null corresponding normal stress
and the principal stresses are those that happen when the orientation of the stress
element is 902 = 45 due to the Mohrs circle simplification. Thus, we got
max = | | 7.0 MPa
min = | | 7.0 MPa
max = | | 7.0 MPa
= 0 MPa
max
(at = 135)
(when = )
min
(at = 45)
ffreitas@uwo.ca
max
45
Jan 21, 2015 8/25
MSE 3380
UWO
Bonus: According to the Distortion Energy Theory, the distortion energy density in terms
of equivalent (von Misses) stress, VM , is given by
=
1+ 2
3 VM
Knowing that the von Mises stress for a two-dimensional plane stress state can be
defined in terms of principal stresses as
2
2
VM = max
max min + min
and once the stresses at correspond to a situation that only shear stress exists, which
means that
max = min =
we got that the yield stress (critical stress value) is
2 + ( ) + 2 = 3
VM =
which means that the material will yield at if the shear stress reaches 13 0.577
of the yield stress.
Thus, given = 60 MPa,
7.0 MPa
60 MPa
3
35 MPa
respect the maximum-distortion-energy (von Mises) condition and will not yield at .
ffreitas@uwo.ca
Jan 21, 2015 9/25
MSE 3380
UWO
2. [Stress-based design] A simply-supported beam is required to support the loads shown,

and the grade of steel to be used has all = 170 MPa and all = 100 MPa. Neglecting the
effect of fillets, stress concentrations, out-of-plane stresses due to the loads and weight of
the bream, determine:
12 kN
6 kN
(a) the reaction forces at the supports.

(b) the maximum magnitudes of the shear force and bending moment.
(c) the required section modulus, min , due to flexure.
(d) the most appropriate standard SI Wide-Flange beam section that should be used from
those listed in the table below.
Shape
Section modulus
[103 mm3 ]
W200 19.3
W150 24
W150 18
W150 13.5
W130 28.1
W130 23.8
W100 19.3
162.0
167.0
120.0
91.1
167.0
140.0
89.5
(e) if the selected beam will fail due to the maximum shear in the web, max
(assume uniform shear stress in the web; note that the table of properties of standard W
sections is attached).
(f) if the selected beam will fail due to the maximum flexural stress on the outermost
surface of the flange, .
Bonus: (+2 point) Determine if the selected beam will fail due to the maximum principal
stress at the web-flange junction, max . Assume uniform shear stress in the web.
ffreitas@uwo.ca
Jan 21, 2015 10/25
MSE 3380
UWO
SOLUTION
(a) Defining the reaction forces at each support as illustrated below in the free body
diagram
12 kN

6 kN
and once the beam is static, the sum of every bending moment about any point must be
zero. Thus, about we have
= 0 (6 kN) (2 m) + (12 kN) (4 m) + (6 m) = 0
= 10 kN
Also, this static situation requires that the sum of the forces in all directions must be
zero, we have
= 0
= 0
= 0 + (6 kN) + (12 kN) + = 0
ffreitas@uwo.ca
= 8 kN
Jan 21, 2015 11/25
MSE 3380
UWO
(b) Analysing the shear forces across the beam, we have that
= 8 kN,
() = { + (6 kN) = 2 kN,
0m <2m
2m <4m
+ (6 kN) + (12 kN) = 10 kN,
4m <6m
Analysing the bending moments across the beam, we have that

= 8 [kNm],
0m <2m
2m <4m
() = { + (6 kN)( 2) = 2 + 12 [kNm],
+ (6 kN)( 2) + (12 kN)( 4) = 10 + 60 [kNm], 4 m 6 m
Thus, the maximum shear force max and the maximum bending moment max are
max = 10 kN
and
ffreitas@uwo.ca
max = 20 kNm
Jan 21, 2015 12/25
MSE 3380
UWO
(c) Knowing the maximum bending moment at 4 m, the correspondent maximum shear
stress at that point is given by
max =
max max
where max is the maximum distance of material of the cross section from the neutral
axis. However, we do not have any information about the cross section of the beam, so
we cannot know . However, we can use the definition of the elastic section modulus
=
max
so that, using the previous equation, we have

max =
max
max
=
max
Once the maximum bending moment was calculated in the last exercise and maximum
shear stress allowed was given, i.e. max = all = 170 MPa, the required minimum
elastic sections modulus is
20 103 Nm
=
118 103 mm3
170 106 Nm2
(d) The most appropriate standard SI Wide-Flange beam section that should be used from
the table given is the one that have the least value of elastic section modulus that is
greater that min , which is the shape W150 18 . This choice often guarantees the
selection of the least expansive beam in the table, once their price generally increases
with greater section modulus. The chosen beams dimensions are shown above:
7.11 mm
102 mm
153 mm
2
5.84 mm
ffreitas@uwo.ca
Jan 21, 2015 13/25
MSE 3380
UWO
(e) We define the maximum shear stress distribution by

max =
max
However, if we assume an uniform shear stress on the beams section, we can define
the maximum shear stress by
max =
max
where is the section area of the web, i.e. = 2 , so that

max =
(10 kN)
12 MPa
(0.00584 m)(0.153 m 2 0.00711 m)
Thus, once
max < all = 100 MPa
the beam chosen will endure the loads without any failing on the web.
ffreitas@uwo.ca
Jan 21, 2015 14/25
MSE 3380
UWO
(f) Now that we have information about the section, we can calculate the real maximum
shear stress at the outermost surface of the flange by
a =
max max
where the second moment of area can be checked within a table or calculated as
0
1 12 )
= 1 + 2 + 3 = (1 +
+ (2 +
1
= { (0.102 m)(0.00711 m)3
12
2 22 )
+ (3 + 3 32 )
1
2
(0.102 m)(0.00711 m) {[0.153

(0.153 m)2} }
+
m (0.00711 m)2]
1
(0.00584 m)(0.153 m 2 0.00711 m)3
12
2
1
+ { (0.102 m)(0.00711 m)3
12
3
2
+ (0.102
m)(0.00711 m) [(0.00711
m)2 (0.153
m)2] }
9.0 10
which does not match exactly with the value 9.20 106 m4 of the table from
Appendix C of [1]. Using the both values, we have
1
(20 103 Nm) [(0.153 m)2]

(9.0 106 m4 )
2 =
170 MPa
(20 103 Nm) [(0.153 m)2]

(9.20 106 m4 )
166 MPa
Once 2 < 1 all = 170 MPa , the chosen beam will (almost) not fail.
Bonus: At the web-flange junction, we have a different = max

= max 0.00711 m
= (0.153 m)2 (0.00711 m) = 0.06939 m, so that
max1
(20 103 Nm) (0.06939 m)

(7.8 106 m4 )
max 2 =
75 MPa
(20 103 Nm) (0.06939 m)

(9.20 106 m4 )
77 MPa
Once max 2 < max1 < all = 170 MPa , the chosen beam will not fail.
[1] F. P. Beer, E. R. Johnston, Jr., J. T. DeWolf, and D. F. Mazurek, Mechanics of Materials, 7th ed.
New York, NY: McGraw-Hill, 2015.
ffreitas@uwo.ca
Jan 21, 2015 15/25
MSE 3380
UWO
3. [Stress analysis in shafts] A torque = 100 Nm is applied to the shaft , which is

running at constant speed and contains gear . Gear transmits torque to shaft
through gear , which drives the chain sprocket at , transmitting a force as shown.
Sprocket , gear , and gear have pitch diameters of = 150 mm, = 250 mm, and
= 125 mm, respectively. The contact force between the gears is transmitted through the
pressure angle = 20. Assuming no frictional losses and considering the bearings at
, , , and to be simple supports, locate the point on shaft that contains the
maximum normal and maximum shear stresses. Combine these stresses and determine the
maximum principal normal and shear stresses in the shaft.
ffreitas@uwo.ca
Jan 21, 2015 16/25
MSE 3380
UWO
SOLUTION
Analysing the first gear, , we have the following free body diagram
1
62.5 mm
= 100 Nm

Gear
Thus, equalling the sum of all the bending moments to zero, we have the following
reaction force
= 0
+ = 0
2
=
2
=
100 Nm
62.5 103 m
= 1.6 kN
and using the geometry of the force , we can calculate its norm by
=
=

cos
1.6 kN
cos 20
1.7 kN
and the norm of the normal force
= tan
= (1.6 kN) tan 20
0.58 kN
ffreitas@uwo.ca
Jan 21, 2015 17/25
MSE 3380
UWO
Using the law of conservation of energy with no frictional losses, the reaction force
calculated in the gear is the same reaction force in the gear with opposite orientation

125 mm
Gear
such that the norms are the same

= 1.7 kN
= = 1.6 kN
= 0.58 kN
and the static give the torque by
= 0

+ = 0
2
=
= (1.6 kN) (125 103 m)

= 200 Nm
This value could also be calculated by using the following relationship between the
diameter (or radius) of both gears

=
=
= (100 Nm) (
250 mm
)
125 mm
= 200 Nm
ffreitas@uwo.ca
Jan 21, 2015 18/25
MSE 3380
UWO
Assuming that this torque is transmitted without losses to the sprocket , we have
equal magnitude and opposite orientation
=
such that we have the following diagram

=
200 Nm
=
200 Nm
0 15 mm
75 mm
125 mm
Determining the force , we have

=
200 Nm
=
0.075 m
= 2. 6 kN
ffreitas@uwo.ca
Jan 21, 2015 19/25
MSE 3380
UWO
Thus, analysing the beam forces in the plane
0.58 kN
= 2. 6 kN
= 75 mm
= 250 mm
= 125 mm
we have the reaction forces given by the equilibrium of the bending moments in
= 0
( + ) + ( + + ) = 0
=
+ ( + )
++
(2. 6 kN) (0.075 m) + (0.58 kN) (0.325 m)
(0.450 m)
0.87 kN
and the equilibrium in the -axis
= 0
+ = 0
= +
2. 6 kN + 0.58 kN 0.87 kN
2.4 kN
This gives us the following shear force distribution in the -plane
2.4 kN,
() = { 0.28 kN,
0.87 kN,
ffreitas@uwo.ca
0 mm < 75 mm
75 mm < 325 mm
325 mm 450 mm
Jan 21, 2015 20/25
MSE 3380
UWO
and the following bending moments distribution in the same plane

()
2.4 [kNm],
0 mm < 75 mm
= { ( 0.075) 0.28 + 0.20 [kNm],

( 0.075) ( 0.325) 0.87 + 0.39 [kNm],
75 mm < 325 mm
325 mm 450 mm
max 2.4 kN from to and max 180 Nm at
Analysing the state of stress at in the plane ,
max
max
Shaft
using the maximum bending moment max , we can calculate the maximum principal
normal stress in the shaft
max =
max ( 2) max ( 2) 2max

=
=
4 4
3
=
2 (180 Nm)
(0.015 m)3
34 MPa
ffreitas@uwo.ca
Jan 21, 2015 21/25
MSE 3380
UWO
and the maximum shear stress

max = max (
max ( 2)
max (2 3 3) ( 2)
= max (
)
( 4 4)
( 4 2)
= max (
8max 3
)
3 3
8 (2.4 103 N) (0.015 m) + 3 (200 Nm)

3 (0.015 m)3
28 MPa
Otherwise, analysing the beam forces in the plane
= 1.6 kN
= 2. 6 kN
= 75 mm
= 250 mm
= 125 mm
we have the reaction forces given by the equilibrium of the bending moments in
= 0
+ ( + ) ( + + ) = 0
=
+ ( + )
++
=
(2. 6 kN) (0.075 mm) + (1.6 kN) (0.325 m)

(0.450 m)
= 0.71 kN
and the equilibrium in the -axis
= 0
+ = 0
= +
= 2. 6 kN 1.6 kN + 0.71 kN
= 1. 7 kN
ffreitas@uwo.ca
Jan 21, 2015 22/25
MSE 3380
UWO
This gives us the following shear force distribution in the -plane

= 1. 7 kN,
() = { = 0. 8 kN,
+ = 0.71 kN,
0 mm < 75 mm
75 mm < 325 mm
325 mm 450 mm
and the following bending moments distribution in the same axis

()
= 1. 7 [kNm],
0 mm < 75 mm
= { ( 0.075) = 0. 8 + 0.20 [kNm],

( 0.075) + ( 0.325) = 0.71 0.32 [kNm],
75 mm < 325 mm
325 mm 450 mm
max = 1. 7 kN from to and max = 133. 3 Nm at
ffreitas@uwo.ca
Jan 21, 2015 23/25
MSE 3380
UWO
Analysing the state of stress at in the plane ,

max
max
Shaft
using the maximum bending moment max , we can calculate the maximum principal
normal stress in the shaft
max =
max ( 2) max ( 2) 2max

=
=
4 4
3
=
2 (133. 3 Nm)
(0.015 m)3
25 MPa
and the maximum shear stress
max = max (
max ( 2)
max (2 3 3) ( 2)
= max (
)
( 4 4)
( 4 2)
= max (
8max 3
)
3 3
8 (1. 7 103 N) (0.015 m) + 3 (200 Nm)
3 (0.015 m)3
26 MPa
ffreitas@uwo.ca
Jan 21, 2015 24/25
MSE 3380
UWO
Plotting in a 3D view, we got the following state of stress at
max 34 MPa
max 28 MPa
max 28 MPa
max 25 MPa
max 26 MPa
ffreitas@uwo.ca
max 26 MPa
Jan 21, 2015 25/25

UWO Mechanical Components Design For Mechatronic Systems (MSE 3380) Sample Problems - Solutions v3

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MSE 3380

Sample Problems (v3)

1. [Stress analysis] A sign of dimensions 2.0 m 1.2 m is supported by a hollow circular

(b) the equivalent force-couple system (, , , , , ) at the centroid of the section

Jan 21, 2015 1/25

Sample Problems (v3)

where = 2.0 m and = 1.2 m

and with respect to the -axis to their centroids

where = 2.0 m and = 1.2 m

Jan 21, 2015 2/25

Sample Problems (v3)

Fernando Freitas Alves

Jan 21, 2015 3/25

Sample Problems (v3)

The cross-sectional area of the pole is

The relevant first moment of area for a hollow-semicircle is given by

where () is the thickness in the -axis

where is the top (or bottom) portion of the members

Fernando Freitas Alves

Jan 21, 2015 4/25

Sample Problems (v3)

Fernando Freitas Alves

Jan 21, 2015 5/25

Sample Problems (v3)

(c) The state of stress at the point is

(4.8 kN) (6.6 m) (0.110 m)

since no force stress this direction

(4.8 kN) (1.5 m) (0.110 m)

Fernando Freitas Alves

Jan 21, 2015 6/25

Sample Problems (v3)

(d) The state of stress at the point is

since no force stress these directions

Fernando Freitas Alves

Jan 21, 2015 7/25

Sample Problems (v3)

(e) Constructing the Mohrs circle, we got that

Fernando Freitas Alves

Jan 21, 2015 8/25

Sample Problems (v3)

Fernando Freitas Alves

Jan 21, 2015 9/25

Sample Problems (v3)

2. [Stress-based design] A simply-supported beam is required to support the loads shown,

(a) the reaction forces at the supports.

Jan 21, 2015 10/25

Sample Problems (v3)

= 0 + (6 kN) + (12 kN) + = 0

Fernando Freitas Alves

Jan 21, 2015 11/25

Sample Problems (v3)

+ (6 kN) + (12 kN) = 10 kN,

Analysing the bending moments across the beam, we have that

Fernando Freitas Alves

Jan 21, 2015 12/25

Sample Problems (v3)

so that, using the previous equation, we have

Fernando Freitas Alves

Jan 21, 2015 13/25

Sample Problems (v3)

(e) We define the maximum shear stress distribution by

where is the section area of the web, i.e. = 2 , so that

Fernando Freitas Alves